Pneumaticaly driven pipe swedging and flaring tools

ABSTRACT

Tools for expanding (i.e., flaring and swedging) the ends of metal tubes are configured for attachment to a powered impact hammer, such as an air hammer. A swedging tool for swedging an end of a metal tube has a swedging body with a die section for expanding the tube when driven thereinto and a flanged shank attached to the swedging body and configured for engagement by a powered impact hammer. A flaring tool for flaring an end of a metal tube includes a flaring body having a die section for flaring the tube when driven thereinto. A flanged shank is attached to the flaring body and configured for engagement by a powered impact hammer. A method for expanding an end of a metal tube entails attaching a die body for expanding the end of the metal tube to a powered impact hammer, aligning the die body with the inner diameter of the metal tube, activating the powered impact hammer, and urging the die body a determined distance into the metal tube.

RELATED APPLICATION

This application is a continuation-in-part and claims the benefit ofpriority of U.S. Nonprovisional application Ser. No. 12/175,460 filed 18Jul. 2008, the entire contents of which are incorporated herein by thisreference and made a part hereof.

FIELD OF THE INVENTION

This invention relates to pipe fitting, and more particularly, to pipeswedging and flaring tools adapted for use with an air hammer andconfigured to expand the end of a first length of metal tube forconnecting the expanded end to a second length of metal tube byreceiving a portion of the second length in the expanded end of thefirst length.

BACKGROUND

Pipe fitting is necessary in many different trades, including, but notlimited to plumbing, HVAC, refrigeration, manufacturing, fireprevention, and many others. Among the most widely used metal pipe iscopper tubing, which is favored for its abundance, ductility and highresistance to corrosion, Copper tubing is most often used for supply ofhot and cold water, and as a refrigerant line in HVAC and refrigerationsystems. Copper tubing is typically joined using a flare connection,compression connection, crimp fitting, sweat (i.e., solder) or swedge.

Flare connections require that the end of a tubing section be spreadoutward in a bell shape using a flare tool. A flare nut then compressesthis bell-shaped end onto a male fitting. Flare connections are laborintensive but are quite reliable over the course of many years.

Sweat fittings are smooth couplings that easily slip onto the end of atubing section. The joint is then heated using a torch, and solder ismelted into the connection. When the solder cools, it forms a verystrong bond.

Compression fittings use a soft metal ring (i.e., a compression ring)which is squeezed onto the pipe and into the fitting by a compressionnut. The soft metal ring conforms to the surface of the tubing and thefitting, and creates a seal. Compression connections are time consumingto make and sometimes require retightening over time to stop leaks.

Crimped or pressed connections use special copper fittings which arepermanently attached to rigid copper tubing with a powered crimper. Thefittings, manufactured with sealant already inside, slide over thetubing to be connected. Substantial pressure is exerted to deform thefitting and compress the sealant against the inner copper tubing,creating a water tight seal.

Swedging is a metal-forming technique in which a receiving end of a tubeis precisely expanded using a die. The mating end of another tube isinserted into the expanded end. The joint is then heated using a torch,and solder is melted into the connection. When the solder cools, itforms a very strong bond.

There are many examples of swedging tools known in the prior art. Forexample, U.S. Pat. No. 2,679,681 to Resler discloses a swedging method.After thinning (i.e., counterboring) the wall of the end of a length oftubing by drilling, the tubing is firmly held by clamping as a punch isurged into the counterbored section. Not only is counterboring timeconsuming, but it is imprecise and conducive to uneven thinning ordamaging of the wall. Also, Resler provides no means to facilitate rapidand repeatable urging of the punch into the thinned wall section.

As another example, U.S. Pat. No. 3,380,285 to Wilson discloses anassembly of nested swedging tools of various sizes for covering a widerange of tubing diameters. To expand a pipe, a chosen swedging tool isdriven by hammer blows. The tool requires manual strikes which tend tobe inconsistent, off-centered and tedious, especially for a professionalwho may have to join many tubing sections in a work day.

As yet another example, U.S. Pat. No. 5,046,349 to Velte discloses alever-actuated expander with means to grip a pipe and urge a conicalmandrel into the open end of the pipe for expansion. Actuation islimited by the manual gripping force of a user. Setting the tube up foruse is tedious. Slippage results in an imperfect flaring.

Still another example is U.S. Pat. No. 6,695,065 to Simpson, et al,which discloses a method of expanding tubing comprising steps ofproviding a length of expandable tubing; locating an expansion tool,such as a cone, in the tubing; and applying impulses to the tool todrive the tool through the tubing and expand the tubing to a largerdiameter. The tubing may be located downhole and may have a solid wallor a slotted wall. Simpson's method is intended for use in expandingtubing used for oil and gas exploration and requires driving mechanismsthat are quite different from handheld pneumatic hammers. Consequently,the Simpson tool does not teach or suggest integration with flangedshank configured for engagement by a powered impact hammer.

What is needed is an easy to use, consistently reliable, powered toolfor swedging or flaring the end of tubing for joining to like tubing.The tool should be configured to work with existing air or electricpowered impact equipment. To avoid slipping, drifting and off-centeredstrikes, the tool should remain connected to the impact equipmentthroughout the swedging or flaring cycle. The invention is directed toovercoming one or more of the problems and solving one or more of theneeds as set forth above.

SUMMARY OF THE INVENTION

To solve one or more of the problems set forth above, in an exemplaryimplementation of the invention, tools for expanding (i.e., flaring andswedging) the ends of metal tubes are provided. The tools are configuredfor attachment to a powered impact hammer, such as an air hammer. Amethod for expanding the ends of metal tubes using such a tool and apowered impact hammer is also provided.

In one aspect of the invention, a swedging tool for expanding an end ofa first metal tube having a first inner diameter and a first outerdiameter is provided. The tool includes a swedging body having a diesection for expanding a tube of predetermined diameter when driventhereinto and a flanged shank attached to the swedging body andconfigured for engagement by a powered impact hammer. A key feature ofthe tool is that it is adapted for attachment to a powered impacthammer, such as an air hammer.

The flanged shank is configured for engagement by a retainer spring of apowered impact hammer. The flanged shank has a cylindrical proximalshank body sized for engagement by a powered impact hammer, a distalshank body, and a flange disposed therebetween. The flange has achamfered trailing edge and a leading edge substantially perpendicularto a longitudinal axis of the swedging tool. The proximal shank body hasa diameter of about 0.40 inches. The distal shank body has a diameter ofabout 0.50 inches. The flange has a diameter of about 0.80 inches. Inone embodiment, the flanged shank is threadedly connected to theswedging body. In other embodiments, the flanged shank is integrallyformed and permanently connected to the swedging body.

In one embodiment, the die section includes a cylindrical first bodysection having a diameter that is approximately equal to the first innerdiameter of the first metal tube, and a cylindrical second body sectionhaving a diameter that is approximately equal to the first outerdiameter of the first metal tube, and a first chamfered transition fromthe first body section to the second body section. In anotherembodiment, the swedging tool is further configured to expand an end ofa second metal tube having a second inner diameter and a second outerdiameter. Thus, the die section further includes a cylindrical thirdbody section having a diameter that is about equal to the second outerdiameter of the second metal tube, and the cylindrical second bodysection having a diameter that is about equal to the second innerdiameter the second metal tube, and a second chamfered transition fromthe second body section to the third body section.

In another embodiment, the swedging tool is further configured to expandan end of a third metal tube having a third inner diameter and a thirdouter diameter. The die section further includes a cylindrical fourthbody section having a diameter that is about equal to the third outerdiameter of the third metal tube. The cylindrical third body section hasa diameter that is about equal to the third inner diameter the thirdmetal tube. A third chamfered transition provides a transition from thethird body section to the fourth body section.

In another aspect of the invention, a flaring tool for flaring an end ofa first metal tube having a first inner diameter and a first outerdiameter is provided. The tool includes a flaring body having a diesection for flaring a tube of predetermined diameter when driventhereinto. A flanged shank is attached to the flaring body andconfigured for engagement by a powered impact hammer. The flanged shank,which is configured for engagement by a retainer spring of a poweredimpact hammer, has a cylindrical proximal shank body sized forengagement by a powered impact hammer, a distal shank body, and a flangedisposed therebetween.

In yet another aspect of the invention, a method for expanding an end ofa metal tube having an inner diameter and an outer diameter is provided.The method includes steps of attaching a die body for expanding the endof the metal tube to a powered impact hammer, aligning the die body withthe inner diameter of the metal tube, activating the powered impacthammer, and urging the die body a determined distance into the metaltube. The die body is either a swedging body having a die section forswedging the end of the metal tube and a flanged shank attached to theswedging body and configured for engagement by a powered impact hammer,or a flaring body having a die section for flaring the end of the metaltube and a flanged shank attached to the flaring body and configured forengagement by a powered impact hammer.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects, objects, features and advantages of theinvention will become better understood with reference to the followingdescription, appended claims, and accompanying drawings, where:

FIG. 1A shows a profile of a first exemplary pipe swedging tool for anair hammer according to principles of the invention; and

FIG. 1B shows a perspective view of the first exemplary pipe swedgingtool for an air hammer according to principles of the invention; and

FIG. 2A shows a profile of a second exemplary pipe swedging tool for anair hammer according to principles of the invention; and

FIG. 2B shows a perspective view of the second exemplary pipe swedgingtool for an air hammer according to principles of the invention; and

FIG. 3A shows a profile of a third exemplary pipe swedging tool for anair hammer according to principles of the invention; and

FIG. 3B shows a perspective view of the third exemplary pipe swedgingtool for an air hammer according to principles of the invention; and

FIG. 4A shows a profile of a first exemplary pipe flaring tool for anair hammer according to principles of the invention; and

FIG. 4B shows a perspective view of the first exemplary pipe flaringtool for an air hammer according to principles of the invention; and

FIG. 5A shows a profile of the first exemplary pipe flaring tool with anoptional threaded coupling for an air hammer according to principles ofthe invention; and

FIG. 5B shows a perspective view of the first exemplary pipe flaringtool with an optional threaded coupling for an air hammer according toprinciples of the invention; and

FIG. 6 shows a perspective view of the first exemplary pipe swedgingtool for an air hammer with an exemplary workpiece according toprinciples of the invention; and

FIG. 7A shows a perspective view of the first exemplary pipe swedgingtool for an air hammer with an exemplary swedged workpiece according toprinciples of the invention; and

FIG. 7B shows a section view of the first exemplary pipe swedging toolfor an air hammer with an exemplary swedged workpiece according toprinciples of the invention; and

FIG. 8A shows a perspective view of an exemplary length of tubing fittedinto a swedged workpiece according to principles of the invention; and

FIG. 8B shows a section view of an exemplary length of tubing fittedinto a swedged workpiece according to principles of the invention; and

FIG. 9 shows a perspective view of the first exemplary pipe swedgingtool installed on an exemplary air hammer according to principles of theinvention; and

FIG. 10 shows a perspective view of a second exemplary pipe flaring toolwith a removable flaring head and a shank coupling for an air hammeraccording to principles of the invention; and

FIG. 11 shows another perspective view of a second exemplary pipeflaring tool with a removable flaring head in an extended position and ashank coupling for an air hammer according to principles of theinvention; and

FIG. 12 shows a perspective exploded view of a second exemplary pipeflaring tool with a removable flaring head and a shank coupling for anair hammer according to principles of the invention.

Those skilled in the art will appreciate that the figures are notintended to be drawn to any particular scale; nor are the figuresintended to illustrate every embodiment of the invention. The inventionis not limited to the exemplary embodiments depicted in the figures orthe types of power tools, relative sizes, ornamental aspects orproportions shown in the figures.

DETAILED DESCRIPTION

Referring to the Figures, in which like parts are indicated with thesame reference numerals, various views of exemplary pipe swedging andflaring tools for an air hammer according to principles of the inventionare shown. Each tool has one or more swedging or flaring sections, eachsection being for a tube of a particular size. Each tool also has ashank adapted for releasable connection to an impact hammer, such as anair or electric powered impact hammer with a spring retainer or collet.Each tool has a tapered leading edge, a body section having a diameterequal to or slightly less than the inner diameter of the tubing, and ametal forming section configured to flare or swedge the tubing as thetool is advanced into the tubing. The tools are preferably comprised ofhardened steel or other material suitable for withstanding therepetitive stresses and strains encountered in the operatingenvironment.

The tools described herein are designed to expand metal pipes or tubes.The terms pipes and tubes are used herein synonymously to mean anelongated hollow fluid carrying means with an inner diameter and anouter diameter. Dimensions provided herein are provided as examples.Some features are designed to fit within the inner diameter of a tube.Some features are designed to be about the same size as the outerdiameter of a tube. Variations in dimensions are possible and intendedto come within the scope of the invention, so long as the varieddimensions do not substantially compromise utility. The principles ofthe invention are not limited to pipes or tubes of any particular size.

Referring first to FIGS. 1A and 1B, profile and perspective views of afirst exemplary pipe swedging tool 100 for an air hammer according toprinciples of the invention are provided. The tool 100 features three(3) swedging sections arranged in tandem. Each swedging section includestwo adjacent body sections of different diameters and a tapered(chamfered) transition therebetween. Each body section is cylindricalwith a diameter d and a length l. The first swedging section commenceswith a tapered (chamfered) leading edge 105 to facilitate entry into theinterior of a tube. The angle α₁₃₁ is obtuse, preferably (but notlimited to) between 10° to 150°, and preferably 112°. The taper 105provides a transition between the distal tip and the first body section135. The first body section 135 has a diameter that is about equal orslightly smaller than the interior diameter of the smallest tubing forwhich the tool 100 is configured to swedge, such that the first bodysection 135 may fit (preferably snugly) within such tubing. By way ofexample and not limitation, the diameter of the first body section mayequal or be about 0.5 inches and the length may equal or be about 0.75inches. The first body section 135 terminates with a chamfered trailingedge 110 configured to provide a transition to the second body section140. The second body section 140 has a diameter that is larger than thediameter of the second body section 140 and is approximately equal to orslightly larger than the outer diameter of the smallest tubing for whichthe tool 100 is configured to swedge. The length of the second bodysection 140 defines the length of the expanded section of tubing. Thus,when urged into the smallest tubing for which the tool 100 is configuredto swedge, the first body section 135 slides into the tubing. As thetool 100 is urged further into the tubing and the free edge of thetubing encounters the chamfered trailing edge 110, the diameter of theengaged portion of the tubing is gradually expanded to the diameter ofthe second body section 140. Thus, the expanded diameter section of thetubing is configured to snugly receive a length of the undeformedsmallest tubing for which the tool 100 is configured to swedge.

With further reference to FIGS. 1A and 1B, the second swedging sectioncommences with a tapered (chamfered) edge 110 to facilitate entry intothe interior of a tube. The angle α₁₃₆ is obtuse, preferably (but notlimited to) between 10° to 150°, and preferably 112°. The taper 110provides a transition between the first body section 135 and the secondbody section 140. The second body section 140 has a diameter that isabout equal or slightly smaller than the interior diameter of anintermediate-sized tubing for which the tool 100 is configured toswedge, such that the second body section 140 may fit (preferablysnugly) within such tubing. By way of example and not limitation, thediameter of the second body section may equal or be about ⅝ inches andthe length may equal or be about 0.75 inches. The second body section140 terminates with a chamfered trailing edge 115 configured to providea transition to the third body section 145. The third body section 145has a diameter that is larger than the diameter of the second bodysection 140 and is approximately equal to or slightly larger than theouter diameter of the intermediate tubing for which the tool 100 isconfigured to swedge. The length of the third body section 145 definesthe length of the expanded section of tubing. Thus, when urged into theintermediate tubing, the third body section 145 slides into the tubing.As the tool 100 is urged further into the tubing and the free edge ofthe tubing encounters the chamfered trailing edge 115, the diameter ofthe engaged portion of the tubing is gradually expanded to the diameterof the third body section 145. Thus, the expanded diameter section ofthe tubing is configured to snugly receive a length of the undeformedintermediate tubing for which the tool 100 is configured to swedge.

With further reference to FIGS. 1A and 1B, the third swedging sectioncommences with a tapered (chamfered) edge 115 to facilitate entry intothe interior of a tube. The angle α₁₄₁ is obtuse, preferably (but notlimited to) between 10° to 150°, and preferably 112°. The taper 115provides a transition between the second body section 135 and the thirdbody section 145. The third body section 145 has a diameter that isabout equal or slightly smaller than the interior diameter of alarge-sized tubing for which the tool 100 is configured to swedge, suchthat the third body section 145 may fit (preferably snugly) within suchtubing. By way of example and not limitation, the diameter of the thirdbody section may equal or be about 0.75 inches and the length may equalor be about 0.75 inches. The third body section 145 terminates with achamfered trailing edge 120 configured to provide a transition to thefourth body section 150. The fourth body section 150 has a diameter thatis larger than the diameter of the third body section 145 and isapproximately equal to or slightly larger than the outer diameter of thelarge tubing for which the tool 100 is configured to swedge. The lengthof the fourth body section 150 defines the length of the expandedsection of tubing. By way of example and not limitation, the diameter ofthe fourth body section may equal or be about ⅞ inches and the lengthmay equal or be about 0.75 inches. Thus, when urged into the largetubing, the fourth body section 150 slides into the tubing. As the tool100 is urged further into the tubing and the free edge of the tubingreaches the chamfered trailing edge 125, the diameter of the engagedportion of the tubing is gradually expanded to the diameter of thefourth body section 150. Thus, the expanded diameter section of thetubing is configured to snugly receive a length of the undeformed largetubing for which the tool 100 is configured to swedge.

The proximal end of the tool 100 comprises a shank configured forengagement by a powered impact tool, such as, but not limited to, an airpowered impact hammer. The shank comprises a distal shank body 155 aretainer 130 and a proximal shank body 160. The retainer 130 is a flangeconfigured for engagement by a spring retainer of an air hammer. Theangle α₁₅₁ of the chamfered transition is not particularly important. Itmay be between 90 and 150°. The proximal shank body 160 may be receivedand engaged by other retention means such as a collet or chuck. Thediameter of the proximal shank body 160 may equal or be about, by way ofexample and not limitation, 0.40 inches. The diameter of the distalshank body 155 may equal or be about, by way of example and notlimitation, 0.50 inches. Thus, the shank is configured for engagement bya spring retainer or other retention means of the powered impact tool.

A portable impact hammer drives the swedging tool into the tubing. Theimpact hammer is a portable percussive hammer powered by compressed gasor an electric motor. A typical pneumatic hammer generates roughly 2,000to 5,000 blows per minute at 90 psi, with a stroke length of 1 to 2inches, which is far greater than any force a human can manually exert.Additionally, the powered hammer exerts forces in a rapid, repeatableand consistent manner. The result is a consistent swedge or flare inminimal time, each time the tool is used.

Referring now to FIGS. 2A and 2B, profile and perspective views of asecond exemplary pipe swedging tool 200 for an air hammer according toprinciples of the invention are provided. The tool 200 features two (2)swedging sections arranged in tandem. Each swedging section includes twoadjacent body sections of different diameters and a tapered (chamfered)transition therebetween. The first swedging section commences with atapered (chamfered) leading edge 205 to facilitate entry into theinterior of a tube. The angle α₂₂₁ is obtuse, preferably (but notlimited to) between 100 to 150°, and preferably 112°. The taper 205provides a transition between the distal tip and the first body section235. The first body section 235 has a diameter that is about equal orslightly smaller than the interior diameter of the smallest tubing forwhich the tool 200 is configured to swedge, such that the first bodysection 235 may fit (preferably snugly) within such tubing. By way ofexample and not limitation, the diameter of the first body section mayequal or be about 0.25 inches and the length may equal or be about 0.75inches. The first body section 225 terminates with a chamfered trailingedge 210 configured to provide a transition to the second body section230. The second body section 230 has a diameter that is larger than thediameter of the second body section 230 and is approximately equal to orslightly larger than the outer diameter of the smallest tubing for whichthe tool 200 is configured to swedge. The length of the second bodysection 230 defines the length of the expanded section of tubing. By wayof example and not limitation, the diameter of the second body sectionmay equal or be about ⅜ inches and the length may equal or be about 0.75inches. Thus, when urged into the smallest tubing for which the tool 200is configured to swedge, the first body section 225 slides into thetubing. As the tool 200 is urged further into the tubing and the freeedge of the tubing encounters the chamfered trailing edge 210, thediameter of the engaged portion of the tubing is gradually expanded tothe diameter of the second body section 230. Thus, the expanded diametersection of the tubing is configured to snugly receive a length of theundeformed smallest tubing for which the tool 200 is configured toswedge.

With further reference to FIGS. 2A and 2B, the second swedging sectioncommences with a tapered (chamfered) edge 210 to facilitate entry intothe interior of a tube. The angle α₂₂₆ is obtuse, preferably (but notlimited to) between 100 to 150°, and preferably 112°. The taper 210provides a transition between the first body section 225 and the secondbody section 230. The second body section 230 has a diameter that isabout equal or slightly smaller than the interior diameter of anintermediate-sized tubing for which the tool 200 is configured toswedge, such that the second body section 230 may fit (preferablysnugly) within such tubing. The second body section 230 terminates witha chamfered trailing edge 215 configured to provide a transition to thethird body section 235. The third body section 235 has a diameter thatis larger than the diameter of the second body section 230 and isapproximately equal to or slightly larger than the outer diameter of theintermediate tubing for which the tool 200 is configured to swedge. Thelength of the third body section 235 defines the length of the expandedsection of tubing. By way of example and not limitation, the diameter ofthe third body section may equal or be about 0.5 inches and the lengthmay equal or be about 1.5 inches. Thus, when urged into the intermediatetubing, the third body section 235 slides into the tubing. As the tool200 is urged further into the tubing and the free edge of the tubingencounters the chamfered trailing edge 215, the diameter of the engagedportion of the tubing is gradually expanded to the diameter of the thirdbody section 235. Thus, the expanded diameter section of the tubing isconfigured to snugly receive a length of the undeformed intermediatetubing for which the tool 200 is configured to swedge.

The proximal end of the tool 200 comprises a shank configured forengagement by a powered impact tool, such as, but not limited to, an airpowered impact hammer. The shank comprises a distal shank body 235 aretainer 220 and a proximal shank body 245. The retainer 220 acts as aflange configured for engagement by a spring retainer of an air hammer.The angle α₂₄₁ of the chamfered transition is not particularlyimportant. It may be between 90 and 150°. The proximal shank body 245may be received and engaged by other retention means such as a collet orchuck. The diameter of the proximal shank body 245 may equal or beabout, by way of example and not limitation, 0.40 inches. The diameterof the distal shank body 235 may equal or be about, by way of exampleand not limitation, 0.50 inches. Thus, the shank is configured forengagement by a spring retainer or other retention means of the poweredimpact tool.

A portable impact hammer drives the swedging tool into the tubing. Theimpact hammer is a portable percussive hammer powered by compressed gasor an electric motor. A typical pneumatic hammer generates roughly 2,000to 5,000 blows per minute at 90 psi, with a stroke length of 1 to 2inches, which is far greater than any force a human can manually exert.Additionally, the powered hammer exerts forces in a rapid, repeatableand consistent manner. The result is a consistent swedge or flare inminimal time, each time the tool is used.

Referring now to FIGS. 3A and 3B, profile and perspective views of afirst exemplary pipe swedging tool 300 for an air hammer according toprinciples of the invention are provided. The tool 300 features three(3) swedging sections arranged in tandem. Each swedging section includestwo adjacent body sections of different diameters and a tapered(chamfered) transition therebetween. The first swedging sectioncommences with a tapered (chamfered) leading edge 305 to facilitateentry into the interior of a tube. The angle α₃₃₆ is obtuse, preferably(but not limited to) between 100 to 150°, and preferably 112°. The taper305 provides a transition between the distal tip and the first bodysection 340. The first body section 340 has a diameter that is aboutequal or slightly smaller than the interior diameter of the smallesttubing for which the tool 300 is configured to swedge, such that thefirst body section 340 may fit (preferably snugly) within such tubing.By way of example and not limitation, the diameter of the first bodysection may equal or be about 0.75 inches and the length may equal or beabout 0.75 inches. The first body section 340 terminates with achamfered trailing edge 310 configured to provide a transition to thesecond body section 345. The second body section 345 has a diameter thatis larger than the diameter of the second body section 345 and isapproximately equal to or slightly larger than the outer diameter of thesmallest tubing for which the tool 300 is configured to swedge. Thelength of the second body section 345 defines the length of the expandedsection of tubing. Thus, when urged into the smallest tubing for whichthe tool 300 is configured to swedge, the first body section 340 slidesinto the tubing. As the tool 300 is urged further into the tubing andthe free edge of the tubing encounters the chamfered trailing edge 310,the diameter of the engaged portion of the tubing is gradually expandedto the diameter of the second body section 345. Thus, the expandeddiameter section of the tubing is configured to snugly receive a lengthof the undeformed smallest tubing for which the tool 300 is configuredto swedge.

With further reference to FIGS. 3A and 3B, the second swedging sectioncommences with a tapered (chamfered) edge 310 to facilitate entry intothe interior of a tube. The angle α₃₄₁ is obtuse, preferably (but notlimited to) between 100 to 150°, and preferably 112°. The taper 310provides a transition between the first body section 340 and the secondbody section 345. The second body section 345 has a diameter that isabout equal or slightly smaller than the interior diameter of anintermediate-sized tubing for which the tool 300 is configured toswedge, such that the second body section 345 may fit (preferablysnugly) within such tubing. By way of example and not limitation, thediameter of the second body section may equal or be about ⅞ inches andthe length may equal or be about 0.75 inches. The second body section345 terminates with a chamfered trailing edge 315 configured to providea transition to the third body section 350. The third body section 350has a diameter that is larger than the diameter of the second bodysection 345 and is approximately equal to or slightly larger than theouter diameter of the intermediate tubing for which the tool 300 isconfigured to swedge. The length of the third body section 350 definesthe length of the expanded section of tubing. Thus, when urged into theintermediate tubing, the third body section 350 slides into the tubing.As the tool 300 is urged further into the tubing and the free edge ofthe tubing encounters the chamfered trailing edge 315, the diameter ofthe engaged portion of the tubing is gradually expanded to the diameterof the third body section 350. Thus, the expanded diameter section ofthe tubing is configured to snugly receive a length of the undeformedintermediate tubing for which the tool 300 is configured to swedge.

With further reference to FIGS. 3A and 3B, the third swedging sectioncommences with a tapered (chamfered) edge 315 to facilitate entry intothe interior of a tube. The angle α₃₄₆ is obtuse, preferably (but notlimited to) between 100 to 150°, and preferably 112°. The taper 315provides a transition between the second body section 340 and the thirdbody section 350. The third body section 350 has a diameter that isabout equal or slightly smaller than the interior diameter of alarge-sized tubing for which the tool 300 is configured to swedge, suchthat the third body section 350 may fit (preferably snugly) within suchtubing. By way of example and not limitation, the diameter of the thirdbody section may be 1 inch and the length may equal or be about 0.75inches. The third body section 350 terminates with a chamfered trailingedge 320 configured to provide a transition to the fourth body section355. The fourth body section 355 has a diameter that is larger than thediameter of the third body section 350 and is approximately equal to orslightly larger than the outer diameter of the large tubing for whichthe tool 300 is configured to swedge. The length of the fourth bodysection 355 defines the length of the expanded section of tubing. By wayof example and not limitation, the diameter of the fourth body sectionmay equal or be about 1.125 inches and the length may equal or be about0.75 inches. Thus, when urged into the large tubing, the fourth bodysection 355 slides into the tubing. As the tool 300 is urged furtherinto the tubing and the free edge of the tubing reaches the chamferedtrailing edge 330, the diameter of the engaged portion of the tubing isgradually expanded to the diameter of the fourth body section 355. Thus,the expanded diameter section of the tubing is configured to snuglyreceive a length of the undeformed large tubing for which the tool 300is configured to swedge.

The proximal end of the tool 300 comprises a shank configured forengagement by a powered impact tool, such as, but not limited to, an airpowered impact hammer. The shank comprises a distal shank body 360 aretainer 335 and a proximal shank body 365. The angle α₃₆₁ of thechamfered transition is not particularly important. It may be between 90and 150°. The retainer 335 acts as a flange configured for engagement bya spring retainer of an air hammer. The proximal shank body 365 may bereceived and engaged by other retention means such as a collet or chuck.The diameter of the proximal shank body 365 may equal or be about, byway of example and not limitation, 0.40 inches. The diameter of thedistal shank body 360 may equal or be about, by way of example and notlimitation, 0.50 inches. Thus, the shank is configured for engagement bya spring retainer or other retention means of the powered impact tool.

A portable impact hammer drives the swedging tool into the tubing. Theimpact hammer is a portable percussive hammer powered by compressed gasor an electric motor. A typical pneumatic hammer generates roughly 2,000to 5,000 blows per minute at 90 psi, with a stroke length of 1 to 2inches, which is far greater than any force a human can manually exert.Additionally, the powered hammer exerts forces in a rapid, repeatableand consistent manner. The result is a consistent swedge or flare inminimal time, each time the tool is used.

Referring now to FIGS. 4A and 4B, profile and perspective views of afirst exemplary pipe flaring tool 400 for an air hammer according toprinciples of the invention are provided. The tool 400 features one (1)flaring section comprising a body section and a tapered (chamfered)trailing edge. The flaring section commences with a tapered (chamfered)leading edge 420 to facilitate entry into the interior of a tube. Theangle α₄₄₁ is obtuse, preferably (but not limited to) between 100 to150°, and preferably 135°. The taper 420 provides a transition betweenthe distal tip and the first body section 440. The body section 440 hasa diameter that is about equal or slightly smaller than the interiordiameter of the smallest tubing for which the tool 400 is configured toflare, such that the first body section 440 may fit (preferably snugly)within such tubing. By way of example and not limitation, the diameterof the body section may equal or be about ¼, ⅜, ½. ⅝, ¾, ⅞, 1 or 1.125inches and the length may equal or be about 0.75 inches. The bodysection 440 terminates with a chamfered trailing edge 415 configured tocreate a flare in the workpiece. Thus, when urged into the smallesttubing for which the tool 400 is configured to flare, the body section440 slides into the tubing. As the tool 400 is urged further into thetubing and the free edge of the tubing encounters the chamfered trailingedge 415, the edge of the tubing is gradually expanded or flared.

The chamfered trailing edges transitions to an intermediate section 435followed by a chamfered transition 410 to a shank. The angle α₄₃₁ of thechamfered transition is not particularly important. It may be between 90and 150°.

The proximal end of the tool 400 comprises a shank configured forengagement by a powered impact tool, such as, but not limited to, an airpowered impact hammer. The shank comprises a distal shank body 440 aretainer 405 and a proximal shank body 425. The retainer 405 acts as aflange configured for engagement by a spring retainer of an air hammer.The angle α₄₂₆ of the chamfered transition is not particularlyimportant. It may be between 90 and 150°. The proximal shank body 425may be received and engaged by other retention means such as a collet orchuck. The diameter of the proximal shank body 425 may equal or beabout, by way of example and not limitation, 0.40 inches. The diameterof the distal shank body 440 may equal or be about, by way of exampleand not limitation, 0.50 inches. Thus, the shank is configured forengagement by a spring retainer or other retention means of the poweredimpact tool.

A portable impact hammer drives the flaring tool into the tubing. Theimpact hammer is a portable percussive hammer powered by compressed gasor an electric motor. A typical pneumatic hammer generates roughly 2,000to 5,000 blows per minute at 90 psi, with a stroke length of 1 to 2inches, which is far greater than any force a human can manually exert.Additionally, the powered hammer exerts forces in a rapid, repeatableand consistent manner. The result is a consistent flare or flare inminimal time, each time the tool is used.

Referring now to FIGS. 5A and 5B, profile and perspective views of analternative embodiment of the first exemplary pipe flaring tool 400 foran air hammer according to principles of the invention are provided. Thetool 400 features one (1) flaring section comprising two adjacent bodysections of different diameters and a tapered (chamfered) transitiontherebetween releasably attachable to a shank section by a threaded male550 and female 555 attachment. Those skilled in the art will appreciatethat any sections of any of the swedging and flaring tool embodimentsmay similarly be releasably attachable. Thus, damaged sections may bereplaced without discarding undamaged sections. Unneeded sections may beremoved to shorten the overall length. The tool may be custom configuredto serve the particular needs of a worker or project.

Referring now to FIGS. 6, 7A, 7B, 8A and 8B, profile and perspectiveviews of the first exemplary pipe swedging tool 100 for an air hammeralong with a length of tubing in various stages of swedging according toprinciples of the invention are provided. The tool 100 features three(3) swedging sections arranged in tandem. Each swedging section includestwo adjacent body sections of different diameters and a tapered(chamfered) transition therebetween. A length of undeformed tubing 600with a central channel 605 is shown in FIG. 6. The inner diameter of thetubing 600 is the same as or slightly larger than the first body section135, so that the tubing 600 may easily slip onto the tool 100. Using apower tool such as a pneumatic impact hammer, the tool 100 is driveninto the tubing 600 until the free edge of the tubing 600 reacheschamfered trailing edge 115, as shown in FIGS. 7A and 7B. The tubing maybe clamped or otherwise held in place as the tool is driven therein. Atthat point, an expanded section 705 and a gradual transition 700 to theundisturbed original diameter have been formed. The inner diameter ofthe expanded section 705 is equal to the outer diameter of the tubing600. Thus, after removing the swedged piece 600, a similar undeformedtubing section 800 may be inserted snugly into the expanded section 705,as shown in FIGS. 8A and 8B. The joint may then be heated using a torchand solder may be melted into the connection. When the solder cools, itforms a very strong bond. Advantageously, only one edge of the joint hasto be soldered.

FIG. 9 illustrates a pneumatic device 900 of the conventional typenormally found in automobile service stations and garages. The deviceincludes a handle 910, a body portion 905 and an actuating means ortrigger 920 for activating the hammer, and an inlet 915 for coupling thedevice to an air supply line. A typical air hammer delivers about 2000to 5000 blows per minute, weighs approximately 3 to 5 pounds andmeasures 8 to 10 inches over all. Threadedly attached to the distal endof the device is a conventional spring retainer element 925 whichengages and holds the various flange-shanked tools of this invention. Asis well known in the art, the spring retainer element has a tightlywound helical portion having a tang extending outwardly from the helixat a tangent and having a bight portion on its distal end to facilitateengagement with a finger or thumb.

Referring now to FIGS. 10, 11 and 12, perspective views of a secondexemplary pipe flaring tool with a removable flaring head and a shankcoupling for an air hammer according to principles of the invention areshown. The tool 1000 features a flaring section comprising a conicalbody section 1050 and a cylindrical skirt 1045. The conical flaringsection 1050 facilitates entry into the interior of any tubes having aninterior diameter smaller than the base diameter of the cone. Thecylindrical skirt 1045 provides a transition between the flaring headand a threaded coupling 1055. The external threads 1080 of the threadedcoupling 1055 are threadedly received by corresponding internal threads1025 of the cylindrical body 1040. A lock nut 1010, which can betightened against the cylindrical body 1040, prevents the threadedcoupling 1055 from working loose from the cylindrical body 1040. A neck1075 of the threaded coupling 1055 has a channel 1065 (or other matingfeature) for receiving a fastening pin 1005 (or other fastener). Theneck 1075 is received in a socket 1070 in the cylindrical skirt 1045.The channel 1070 in the neck 1075 aligns with a channel through thecylindrical skirt 1045, when the neck 1075 is received in a socket 1070in the cylindrical skirt 1045 and the neck 1075 is oriented relative tothe cylindrical skirt 1045 for alignment. A fastening pin may be pressedinto the channel 1060 of the cylindrical skirt 1045 as well as thealigned channel 1065 of the neck 1075, thereby fastening the flaringhead to the threaded coupling 1055. The distance between the flaringhead and the cylindrical body 1040 may readily be adjusted by turningthe threaded coupling 1055 relative to the threaded body 1040.Additionally, the flaring head may be replaced with an alternativeflaring head, swedging head or other impact driven pipe fitting die inaccordance with principles of the invention. The cylindrical body 1040terminates with a chamfered trailing edge 1015 which transitions to theproximal end of the tool 100 comprising a shank configured forengagement by a powered impact tool, such as, but not limited to, an airpowered impact hammer.

The shank comprises a distal shank body 1035 a retainer 1020 and aproximal shank body 1030. The retainer 1020 acts as a flange configuredfor engagement by a spring retainer of an air hammer. The proximal shankbody 1030 may be received and engaged by other retention means such as acollet or chuck. The diameter of the proximal shank body 1030 may equalor be about, by way of example and not limitation, 0.40 inches. Thediameter of the distal shank body 1035 may equal or be about, by way ofexample and not limitation, 0.50 inches. Thus, the shank is configuredfor engagement by a spring retainer or other retention means of thepowered impact tool.

A portable impact hammer drives the flaring tool into the tubing. Theimpact hammer is a portable percussive hammer powered by compressed gasor an electric motor. A typical pneumatic hammer generates roughly 2,000to 5,000 blows per minute at 90 psi, with a stroke length of 1 to 2inches, which is far greater than any force a human can manually exert.Additionally, the powered hammer exerts forces in a rapid, repeatableand consistent manner. The result is a consistent flare or flare inminimal time, each time the tool is used.

Flaring and swedging tools in accordance with principles of theinvention are not limited to use with any tools for clamping andsecuring tubing sections. Flaring and swedging tools in accordance withprinciples of the invention may be used with any tools for clamping andsecuring tubing sections. Flaring and swedging tools in accordance withprinciples of the invention may also be used without any tools forclamping and securing tubing sections, such as by hand holding thetubing sections or by flaring or swedging exposed sections of installedtubing.

While an exemplary embodiment of the invention has been described, itshould be apparent that modifications and variations thereto arepossible, all of which fall within the true spirit and scope of theinvention. With respect to the above description then, it is to berealized that the optimum relationships for the components and steps ofthe invention, including variations in order, form, content, functionand manner of operation, are deemed readily apparent and obvious to oneskilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention. The abovedescription and drawings are illustrative of modifications that can bemade without departing from the present invention, the scope of which isto be limited only by the following claims. Therefore, the foregoing isconsidered as illustrative only of the principles of the invention.Further, since numerous modifications and changes will readily occur tothose skilled in the art, it is not desired to limit the invention tothe exact construction and operation shown and described, andaccordingly, all suitable modifications and equivalents are intended tofall within the scope of the invention as claimed.

1. A swedging tool for expanding an end of a first metal tube having afirst inner diameter and a first outer diameter comprising a swedgingbody having a die section for expanding the first metal tube when driventhereinto; and a flanged shank attached to said swedging body andconfigured for engagement by a powered impact hammer.
 2. A swedging toolaccording to claim 1, said flanged shank being configured for engagementby a retainer spring of a powered impact hammer.
 3. A swedging toolaccording to claim 2, said flanged shank having a cylindrical proximalshank body sized for engagement by a powered impact hammer, a distalshank body, and a flange disposed therebetween.
 4. A swedging toolaccording to claim 3, said flange having a chamfered trailing edge and aleading edge substantially perpendicular to a longitudinal axis of theswedging tool.
 5. A swedging tool according to claim 4, said proximalshank body having a diameter of about 0.40 inches.
 6. A swedging toolaccording to claim 4, said distal shank body having a diameter of about0.50 inches.
 7. A swedging tool according to claim 4, said flange havinga diameter of about 0.80 inches.
 8. A swedging tool according to claim4, said proximal shank body having a diameter of about 0.40 inches andsaid distal shank body having a diameter of about 0.50 inches.
 9. Aswedging tool according to claim 4, said proximal shank body having adiameter of about 0.40 inches and said distal shank body having adiameter of about 0.50 inches, and said flange having a diameter ofabout 0.80 inches.
 10. A swedging tool according to claim 1, saidflanged shank being threadedly connected to the swedging body.
 11. Aswedging tool according to claim 1, said flanged shank being integrallyformed and permanently connected to the swedging body.
 12. A swedgingtool according to claim 1, said die section comprising a cylindricalfirst body section having a diameter that is approximately equal to thefirst inner diameter of the first metal tube, and a cylindrical secondbody section having a diameter that is approximately equal to the firstouter diameter of the first metal tube.
 13. A swedging tool according toclaim 1, said die section comprising a cylindrical first body sectionhaving a diameter that is equal to the first inner diameter of the firstmetal tube, and a cylindrical second body section having a diameter thatis equal to the first outer diameter the first metal tube, and a firstchamfered transition from said first body section to said second bodysection.
 14. A swedging tool according to claim 13, said swedging toolbeing further configured to expand an end of a second metal tube havinga second inner diameter and a second outer diameter, said die sectionfurther comprising a cylindrical third body section having a diameterthat is about equal to the second outer diameter of the second metaltube, and said cylindrical second body section having a diameter that isabout equal to the second inner diameter the second metal tube, and asecond chamfered transition from said second body section to said thirdbody section.
 15. A swedging tool according to claim 14, said swedgingtool being further configured to expand an end of a third metal tubehaving a third inner diameter and a third outer diameter, said diesection further comprising a cylindrical fourth body section having adiameter that is about equal to the third outer diameter of the thirdmetal tube, and said cylindrical third body section having a diameterthat is about equal to the third inner diameter the third metal tube,and a third chamfered transition from said third body section to saidfourth body section.
 16. A flaring tool for flaring an end of a firstmetal tube having a first inner diameter and a first outer diametercomprising a flaring body having a die section for flaring a tube ofpredetermined diameter when driven thereinto; and a flanged shankattached to said flaring body and configured for engagement by a poweredimpact hammer.
 17. A flaring tool according to claim 16, said flangedshank being configured for engagement by a retainer spring of a poweredimpact hammer.
 18. A flaring tool according to claim 17, said flangedshank having a cylindrical proximal shank body sized for engagement by apowered impact hammer, a distal shank body, and a flange disposedtherebetween.
 19. A method for expanding an end of a metal tube havingan inner diameter and an outer diameter comprising steps of attaching adie body for expanding the end of the metal tube to a powered impacthammer, aligning the die body with the inner diameter of the metal tube,activating the powered impact hammer, and urging the die body adetermined distance into the metal tube.
 20. A method for expanding anend of a metal tube according to claim 19, wherein said die bodycomprises a tool from the group consisting of: a swedging body having adie section for swedging the end of the metal tube and a flanged shankattached to said swedging body and configured for engagement by apowered impact hammer; and a flaring body having a die section forflaring the end of the metal tube and a flanged shank attached to saidflaring body and configured for engagement by a powered impact hammer.